Filter Backwashing Unit with Dynamic Dust Thickness Control
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Solution Overview
Problem
The existing filter backwashing unit fails to consistently remove dust from filter elements due to variable dirt coefficients, leading to increased pressure drop and performance degradation, and higher frequency of backwashing which accelerates device degradation and increases nitrogen gas consumption.
Innovation Solution
A filter backwashing unit with a gas injection device, parameter detection device, and control device that estimates dust thickness based on detected parameters to determine optimal backwash intervals, reducing the frequency of backwashing and nitrogen gas consumption while maintaining filter performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the backwash frequency is increased to maintain filter performance, then dust removal effectiveness is improved, but device degradation accelerates and nitrogen gas consumption increases
Solution Approach 1:
The backwash frequency is made dynamic rather than fixed. The control device adjusts the backwash timing based on real-time dust thickness measurements, performing backwash only when dust accumulation reaches a threshold that actually impacts performance. This dynamic adaptation resolves the contradiction by avoiding unnecessary backwashes that degrade the device while ensuring backwash occurs when truly needed for performance maintenance.
Solution Approach 2:
A feedback mechanism is implemented where the dust thickness detection device continuously monitors the element surface and provides data to the control device. The control device uses this feedback to determine optimal backwash timing, creating a closed-loop system that adjusts backwash frequency based on actual dust accumulation conditions rather than following a predetermined schedule, thus balancing performance maintenance with device longevity.
2Reliability
If the backwash frequency is increased to maintain filter performance, then dust removal effectiveness is improved, but nitrogen gas consumption increases
Solution Approach 1:
The backwash operation frequency is dynamically adjusted based on measured dust thickness. Instead of performing backwash at fixed intervals regardless of actual dust accumulation, the system performs backwash only when the detection device confirms dust thickness reaches a level that impacts performance. This dynamic approach reduces unnecessary nitrogen gas consumption while maintaining filter performance.
Solution Approach 2:
The dust thickness detection device provides continuous feedback to the control device about actual dust accumulation on the element. This feedback enables the control device to make informed decisions about when backwash is truly necessary, preventing wasteful nitrogen gas consumption from premature or unnecessary backwash operations while ensuring performance is maintained through timely backwash when dust accumulation actually occurs.
3Quantity of substance
If the backwash frequency is decreased to reduce nitrogen gas consumption, then resource usage is optimized, but dust deposition thickness increases and fills the space between elements
Solution Approach 1:
The dust thickness detection device provides real-time feedback on dust accumulation levels, enabling the control device to identify the precise moment when dust thickness becomes problematic. This feedback mechanism ensures backwash is performed at the optimal timing - just before dust accumulation reaches levels that would fill spaces between elements and harm performance - thus avoiding both premature backwash (wasting nitrogen) and delayed backwash (allowing harmful dust accumulation).
Solution Approach 2:
The detection device enables the system to self-regulate backwash timing based on actual dust accumulation conditions. The control device autonomously decides when backwash is needed by monitoring dust thickness measurements, performing backwash only when the element itself indicates it needs cleaning. This self-service approach optimizes nitrogen gas consumption by eliminating unnecessary backwashes while preventing harmful dust accumulation.
4Ease of operation
If fixed backwash intervals are used, then operation is simplified, but dust thickness variation is not accounted for leading to suboptimal performance
Solution Approach 1:
A feedback mechanism using the dust thickness detection device provides real-time information about actual dust accumulation conditions. The control device uses this feedback to dynamically adjust backwash timing, replacing fixed intervals with condition-based timing. This maintains operational simplicity through automated control while significantly improving performance by adapting to actual dust accumulation rates that vary with operating conditions.
Solution Approach 2:
The backwash control transitions from static fixed intervals to dynamic condition-based timing. The control device adjusts backwash frequency based on real-time dust thickness measurements, allowing the system to adapt to varying dust accumulation rates caused by different operating conditions, dust loads, and gas flow rates, thereby maintaining optimal performance without complicating operation through manual intervention.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for timely recovery of filter performance, reduces device degradation, and optimizes nitrogen gas usage by setting longer backwash intervals based on actual dust deposition, preventing excessive wear on valve components.
Implementation Method 1
a gas injection device configured to inject backwashing gas toward the element from the downstream side
Implementation Method 2
a parameter detection device configured to detect a parameter used for determination of a state of dust adhering to the element
Implementation Method 3
a control device configured to estimate a thickness of dust deposited on a surface of an element on an upstream side of a process gas based on a result of detection obtained by the parameter detection device
Data Source
AI summary
A filter backwashing unit is disposed in a path in which process gas flows to remove at least a part of trapped dust included in a process gas by backwashing an element of a filter device that traps the dust when a process gas passes. The filter backwashing unit includes a gas injection device disposed downstream of the element in a flow direction of a process gas to inject backwashing gas toward the element from downstream; a parameter detection device configured to detect a parameter used for determination of a state of dust adhering to the element; and a control device configured to estimate a thickness of dust deposited on a surface of the element upstream of a process gas based on a result of the detection, and determine an interval at which the element is backwashed based on the estimated thickness of the dust.